Mineral fiber product

ABSTRACT

The present invention is directed to a mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde.

FIELD OF THE INVENTION

The present invention relates to a mineral fibre product comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition, and the use of a lignin component in form of one or more lignosulfonate lignins for the preparation of a binder composition.

BACKGROUND OF THE INVENTION

Mineral fibre products generally comprise man-made vitreous fibres (MMVF) such as, e.g., glass fibres, ceramic fibres, basalt fibres, slag wool, mineral wool and stone wool, which are bonded together by a cured thermoset polymeric binder material. For use as thermal or acoustical insulation products, bonded mineral fibre mats are generally produced by converting a melt made of suitable raw materials to fibres in conventional manner, for instance by a spinning cup process or by a cascade rotor process. The fibres are blown into a forming chamber and, while airborne and while still hot, are sprayed with a binder solution and randomly deposited as a mat or web onto a travelling conveyor. The fibre mat is then transferred to a curing oven where heated air is blown through the mat to cure the binder and rigidly bond the mineral fibres together.

In the past, the binder resins of choice have been phenol-formaldehyde resins which can be economically produced and can be extended with urea prior to use as a binder. However, the existing and proposed legislation directed to the lowering or elimination of formaldehyde emissions have led to the development of formaldehyde-free binders such as, for instance, the binder compositions based on polycarboxy polymers and polyols or polyamines, such as disclosed in EP-A-583086, EP-A-990727, EP-A-1741726, US-A-5,318,990 and US-A-2007/0173588.

Another group of non-phenol-formaldehyde binders are the addition/-elimination reaction products of aliphatic and/or aromatic anhydrides with alkanolamines, e.g., as disclosed in WO 99/36368, WO 01/05725, WO 01/96460, WO 02/06178, WO 2004/007615 and WO 2006/061249. These binder compositions are water soluble and exhibit excellent binding properties in terms of curing speed and curing density. WO 2008/023032 discloses urea-modified binders of that type which provide mineral wool products having reduced moisture take-up.

Since some of the starting materials used in the production of these binders are rather expensive chemicals, there is an ongoing need to provide formaldehyde-free binders which are economically produced.

A further effect in connection with previously known aqueous binder compositions from mineral fibres is that at least the majority of the starting materials used for the productions of these binders stem from fossil fuels. There is an ongoing trend of consumers to prefer products that are fully or at least partly produced from renewable materials and there is therefore a need to provide binders for mineral wool which are, at least partly, produced from renewable materials.

A further effect in connection with previously known aqueous binder compositions for mineral fibres is that they involve components which are corrosive and/or harmful. This requires protective measures for the machinery involved in the production of mineral wool products to prevent corrosion and also requires safety measures for the persons handling this machinery. This leads to increased costs and health issues and there is therefore a need to provide binder compositions for mineral fibres with a reduced content of corrosive and/or harmful materials.

In recent times, a number of binders for mineral fibres have been provided, which are to a large extend based on renewable starting materials. In many cases these binder based to a large extent on renewable resources are also formaldehyde-free.

However, many of these binders are still comparatively expensive because they are based on comparatively expensive basic materials.

In the meantime, binders for mineral fibres have been provided, which are based on lignin components which have been oxidised in order to make them suitable as components of a binder composition for mineral wool. While very good binding properties are achieved by these mineral wool binders based on pre-oxidised lignins, the preparation of such binders still requires the extra step of oxidising the lignin components before they can be used as components for the binder compositions. This pre-oxidation step necessary for utilising the lignin components complicates the production process for such binders to a certain extent by increasing the reaction time, reducing the output and increases the costs for such binders due to extra cost for raw materials, process equipment and manning.

SUMMARY OF THE INVENTION

Accordingly, it was an object of the present invention to provide a mineral wool product comprising mineral fibres in contact with a binder resulting from the curing of a binder composition suitable for bonding mineral fibres, which uses renewable materials as starting materials, reduces or eliminates corrosive and/or harmful materials, and is inexpensive to produce.

It was a further object of the present invention to provide a mineral wool product comprising mineral fibres in contact with a binder resulting from the curing of a binder composition suitable for bonding mineral fibres, which allows an increased solid content (and thereby lowered transport costs and less impact on the environment), a reduced viscosity (which makes it easier to process in large scale), and a long shelf life.

Further the present invention provides the use of a lignin component for the preparation of a binder composition for mineral wool.

In accordance with a first aspect of the present invention, there is provided a mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers.

In particular, in accordance with a first aspect of the present invention, there is provided a mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition, preferably free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers,

with the proviso that the aqueous binder composition does not comprise a cross-linker selected from

-   epoxy compounds having a molecular weight Mw of 500 or less -   carbonyl compounds selected from aldehydes, carbonyl compounds of     the formula R—[C(O)R₁]_(x) in which:     -   R represents a saturated or unsaturated and linear, branched or         cyclic hydrocarbon radical, a radical including one or more         aromatic nuclei which consist of 5 or 6 carbon atoms, a radical         including one or more aromatic heterocycles containing 4 or 5         carbon atoms and an oxygen, nitrogen or sulfur atom, it being         possible for the R radical to contain other functional groups,     -   R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and     -   x varies from 1 to 10, -   polyamines -   mono- and oligosaccharides.

In accordance with a second aspect of the present invention, there is provided a use of a lignin component in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins, for the preparations of a binder composition for mineral wool.

In particular, according with the second aspect of the present invention, there is provided a use of a lignin component in form of one or more lignosulfonate lignins and having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins for the preparations of a binder composition for mineral wool with the proviso that the composition does not comprise

-   epoxy compounds having a molecular weight Mw of 500 or less -   carbonyl compounds selected from aldehydes, carbonyl compounds of     the formula R—[C(O)R₁]_(x) in which:     -   R represents a saturated or unsaturated and linear, branched or         cyclic hydrocarbon radical, a radical including one or more         aromatic nuclei which consist of 5 or 6 carbon atoms, a radical         including one or more aromatic heterocycles containing 4 or 5         carbon atoms and an oxygen, nitrogen or sulfur atom, it being         possible for the R radical to contain other functional groups,     -   R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and     -   x varies from 1 to 10, -   polyamines -   mono- and oligosaccharides.

The present inventors have surprisingly found that it is possible to provide a mineral wool product comprising mineral fibres bound by a binder resulting from the curing of a binder composition, whereby the binder composition can be produced from inexpensive renewable materials, in form of a lignin component, which does not require an oxidation step previous to the use in the binder composition and, to a large degree, does not contain, or contains only to a minor degree, any corrosive and/or harmful agents.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The mineral wool product according to the present invention comprises mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers.

In particular, in accordance with a first aspect of the present invention, there is provided a mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers, with the     proviso that the aqueous binder composition does not comprise a     cross-linker selected from     -   epoxy compounds having a molecular weight Mw of 500 or less.

In particular, in accordance with a first aspect of the present invention, there is provided mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers, with the     proviso that the aqueous binder composition does not comprise a     cross-linker selected from     -   carbonyl compounds selected from aldehydes, carbonyl compounds         of the formula R—[C(O)R₁]_(x) in which:         -   R represents a saturated or unsaturated and linear, branched             or cyclic hydrocarbon radical, a radical including one or             more aromatic nuclei which consist of 5 or 6 carbon atoms, a             radical including one or more aromatic heterocycles             containing 4 or 5 carbon atoms and an oxygen, nitrogen or             sulfur atom, it being possible for the R radical to contain             other functional groups,         -   R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and         -   x varies from 1 to 10.

In particular, in accordance with a first aspect of the present invention, there is provided mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers, with the     proviso that the aqueous binder composition does not comprise a     cross-linker selected from     -   polyamines.

In particular, in accordance with a first aspect of the present invention, there is provided mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers, with the     proviso that the aqueous binder composition does not comprise a     cross-linker selected from     -   mono- and oligosaccharides.

In one embodiment, the mineral wool product according to the present invention comprises mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins, -   a component (ii) in form of one or more cross-linkers selected from     -   β-hydroxyalkylamide-cross-linkers, and/or     -   epoxy compounds having a molecular weight of more than 500, such         as an epoxidised oil based on fatty acid triglyceride or one or         more flexible oligomer or polymer, such as a low Tg acrylic         based polymer, such as a low Tg vinyl based polymer, such as low         Tg polyether, which contains reactive functional groups such as         carbodiimide groups, such as anhydride groups, such as oxazoline         groups, such as amino groups, such as epoxy groups, and/or     -   one or more cross-linkers in form of multifunctional         carbodiimides, such as aliphatic multifunctional carbodiimides;         and/or     -   Primid XL-552; -   a component (iii) in form of one or more plasticizers, with the     proviso that the aqueous binder composition does not comprise a     cross-linker selected from     -   epoxy compounds having a molecular weight Mw of 500 or less     -   carbonyl compounds selected from aldehydes, carbonyl compounds         of the formula R-[C(O)R₁]_(x) in which:         -   R represents a saturated or unsaturated and linear, branched             or cyclic hydrocarbon radical, a radical including one or             more aromatic nuclei which consist of 5 or 6 carbon atoms, a             radical including one or more aromatic heterocycles             containing 4 or 5 carbon atoms and an oxygen, nitrogen or             sulfur atom, it being possible for the R radical to contain             other functional groups,         -   R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and         -   x varies from 1 to 10,     -   polyamines.

In a preferred embodiment, the binders are formaldehyde free.

For the purpose of the present application, the term “formaldehyde free” is defined to characterize a mineral wool product where the emission is below 5 µg/m²/h of formaldehyde from the mineral wool product, preferably below 3 µg/m²/h. Preferably, the test is carried out in accordance with ISO 16000 for testing aldehyde emissions.

In a preferred embodiment, the binders are phenol free.

For the purpose of the present application, the term “phenol free” is defined in such a way that the aqueous binder composition does contain phenol

in an amount of ≤ 0.25 wt.-%, such as ≤ 0.1 wt.-%, such as ≤ 0.05 wt.-%, based on the total weight of an aqueous composition having a dry solids binder content of 15 wt.%.

In one embodiment, the binder composition does not contain added formaldehyde.

In one embodiment, the binder composition does not contain added phenol.

For the purpose of the present invention, the term “mono- and oligosaccharides” is defined to comprise monosaccharides and oligosaccharides having 10 or less saccharide units.

For the purpose of the present invention, the term “sugar” is defined to comprise monosaccharides and oligosaccharides having 10 or less saccharide units.

Component (I)

Component (i) is in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins.

Lignin, cellulose and hemicellulose are the three main organic compounds in a plant cell wall. Lignin can be thought of as the glue, that holds the cellulose fibres together. Lignin contains both hydrophilic and hydrophobic groups. It is the second most abundant natural polymer in the world, second only to cellulose, and is estimated to represent as much as 20-30% of the total carbon contained in the biomass, which is more than 1 billion tons globally.

The lignosulfonate process introduces large amount of sulfonate groups making the lignin soluble in water but also in acidic water solutions. Lignosulfonates has up to 8% sulfur as sulfonate, whereas kraft lignin has 1-2% sulfur, mostly bonded to the lignin. The molecular weight of lignosulfonate is 15.000-50.000 g/mol. The typical hydrophobic core of lignin together with large number of ionized sulfonate groups make this lignin attractive as a surfactant and it often finds application in dispersing cement etc.

To produce lignin-based value-added products, lignin should be first separated from biomass, for which several methods can be employed. Kraft and sulfite pulping processes are known for their effective lignin separation from wood, and hence, are used worldwide. Kraft lignin is separated from wood with the help of NaOH and Na2S. Lignins from sulfite pulping processes are denoted as lignosulfonates, and are produced by using sulfurous acid and/or a sulfite salt containing magnesium, calcium, sodium, or ammonium at varying pH levels. Currently, lignosulfonates account for 90% of the total market of commercial lignin, and the total annual worldwide production of lignosulfonates is approximately 1.8 million tons. Lignosulfonates have generally abundance of sulfonic groups, and thus, a higher amount of sulfur than kraft lignin. Due to the presence of the sulfonated group, lignosulfonates are anionically charged and water soluble. The molecular weights (Mw) of lignosulfonates can be similar to or larger than that of kraft lignin. Due to their unique properties, lignosulfonates have a wide range of uses, such as animal feed, pesticides, surfactants, additives in oil drilling, stabilizers in colloidal suspensions, and as plasticizers in concrete admixtures. However, the majority of new pulp mills employ kraft technology for pulp production, and thus, kraft lignin is more readily available for value-added production.

However, lignosulfonates and kraft lignin have different properties coming from different isolation processes and thus distribution of functional groups. High level of sulfonic groups in lignosulfonates, generally at least one for every four C9 units, makes lignosulfonates strongly charged at all pH levels in water. This abundance of ionisable functional groups can explain most of the differences compared to other technical lignins. Higher charge density allows easier water solubility and higher solid content in solution possible compared to kraft lignin. Also, for the same reason, lignosulfonates will have lower solution viscosity compared to kraft lignin at the same solid content which can facilitate handling and processing. Commonly used model structure of lignosulfonates is shown on FIG. 1 .

In one embodiment, component (i) is having a carboxylic acid group content of 0.05 to 0.6 mmol/g, such as 0.1 to 0.4 mmol/g, based on the dry weight of lignosulfonate lignins.

In one embodiment, component (i) is in form of one or more lignosulfonate lignins having an average carboxylic acid group content of less than 1.8 groups per macromolecule considering the M_n wt. average of component (i), such as less than 1.4 such as less than 1.1 such as less than 0.7 such as less than 0.4.

In one embodiment, component (i) is having a content of phenolic OH groups of 0.3 to 2.5 mmol/g, such as 0.5 to 2.0 mmol/g, such as 0.5 to 1.5 mmol/g. based on the dry weight of lignosulfonate lignins.

In one embodiment, component (i) is having a content of aliphatic OH groups of 1.0 to 8.0 mmol/g, such as 1.5 to 6.0 mmol/g, such as 2.0 to 5.0 mmol/g, based on the dry weight of lignosulfonate lignins.

In one embodiment, component (i) comprises ammoniumlignosulfonates and/or calciumlignosulfonates, and/or magnesiumlignosulfonates, and any combinations thereof.

In one embodiment, component (i) comprises ammoniumlignosulfonates and calciumlignosulfonates, wherein the molar ratio of NH₄ ⁺ to Ca²⁺ is in the range of 5:1 to 1:5, in particular 3:1 to 1:3.

For the purpose of the present invention, the term lignosulfonates encompasses sulfonated kraft lignins.

In one embodiment, component (i) is a sulfonated kraft lignins.

In one embodiment, the aqueous binder composition contains added sugar in an amount of 0 to 5 wt.-%, such as less than 5 wt.-%, such as 0 to 4.9 wt.-%, such as 0.1 to 4.9 wt.-%, based on the weight of lignosulfonate and sugar.

In one embodiment, the aqueous binder composition comprises component (i), i.e. the lignosulfonate, in an amount of 50 to 98 wt.-%, such as 65 to 98 wt.-%, such as 80 to 98 wt.-%, based on the total weight of components (i) and (ii).

In one embodiment, the aqueous binder composition comprises component (i) in an amount of 50 to 98 wt.-%, such as 65 to 98 wt.-%, such as 80 to 98 wt.-%, based on the dry weight of components (i), (ii), and (iii).

For the purpose of the present invention, content of lignin functional groups is determined by using ³¹P NMR as characterization method.

Sample preparation for ³¹P NMR is performed by using 2-chloro-4,4,5,5-tetramethyl-1,3,2-dioxaphospholane (TMDP) as phosphitylation reagent and cholesterol as internal standard. Integration is according to the work of Granata and Argyropoulos (J. Agric. Food Chem. 43:1538-1544).

Component (II)

Component (ii) is in form of one or more cross-linkers.

In one embodiment, the component (ii) comprises in one embodiment one or more cross-linkers selected from β-hydroxyalkylamide-cross-linkers and/or oxazoline-cross-linkers.

β-hydroxyalkylamide-cross-linkers is a curing agent for the acid-functional macromolecules. It provides a hard, durable, corrosion resistant and solvent resistant cross-linked polymer network. It is believed the β-hydroxyalkylamide cross-linkers cure through esterification reaction to form multiple ester linkages. The hydroxy functionality of the β-hydroxyalkylamide-cross-linkers should be an average of at least 2, preferably greater than 2 and more preferably 2-4 in order to obtain optimum curing response.

Oxazoline group containing cross-linkers are polymers containing one of more oxazoline groups in each molecule and generally, oxazoline containing cross-linkers can easily be obtained by polymerizing an oxazoline derivative. The patent US 6 818 699 B2 provides a disclosure for such a process.

In one embodiment, the component (ii) is one or more epoxy compounds having a molecular weight of more than 500, such as an epoxidised oil based on fatty acid triglyceride or one or more flexible oligomer or polymer, such as a low Tg acrylic based polymer, such as a low Tg vinyl based polymer, such as low Tg polyether, which contains reactive functional groups such as carbodiimide groups, such as anhydride groups, such as oxazoline groups, such as amino groups, such as epoxy groups, such as β-hydroxyalkylamide groups.

In one embodiment, component (ii) is one or more cross-linkers selected from the group consisting of fatty amines.

In one embodiment, component (ii) is one or more cross-linkers in form of fatty amides.

In one embodiment, component (ii) is one or more cross-linkers selected from polyester polyols, such as polycaprolactone.

In one embodiment, component (ii) is one or more cross-linkers selected from the group consisting of starch, modified starch, CMC.

In one embodiment, component (ii) is one or more cross-linkers in form of multifunctional carbodiimides, such as aliphatic multifunctional carbodiimides.

In one embodiment, the component (ii) is one or more cross-linkers in form of aziridines, such as CX100, NeoAdd-Pax 521/523.

In one embodiment, component (ii) is one or more cross-linkers selected from melamine based cross-linkers, such as a hexakis(methylmethoxy)melamine (HMMM) based cross-linkers.

Examples of such compounds are Picassian XL 701, 702, 725 (Stahl Polymers), such as ZOLDINE® XL-29SE (Angus Chemical Company), such as CX300 (DSM), such as Carbodilite V-02-L2 (Nisshinbo Chemical Inc.).

In one embodiment, component (ii) is Primid XL552, which has the following structure:

Component (ii) can also be any mixture of the above mentioned compounds.

In one embodiment, the binder composition according to the present invention comprises component (ii) in an amount of 1 to 50 wt.-%, such as 4 to 20 wt.-%, such as 6 to 12 wt.-%, based on the dry weight of component (i).

Component (iii) of the binder composition

Optionally and preferably, the binder composition may comprise a component (iii). Component (iii) is in form of one or more plasticizers.

In one embodiment, component (iii) is in form of one or more plasticizers selected from the group consisting of polyols, such as carbohydrates, hydrogenated sugars, such as sorbitol, erythriol, glycerol, monoethylene glycol, polyethylene glycols, polyethylene glycol ethers, polyethers, phthalates and/or acids, such as adipic acid, vanillic acid, lactic acid and/or ferullic acid, acrylic polymers, polyvinyl alcohol, polyurethane dispersions, ethylene carbonate, propylene carbonate, lactones, lactams, lactides, acrylic based polymers with free carboxy groups and/or polyurethane dispersions with free carboxy groups, polyamides, amides such as carbamide/urea, or any mixtures thereof.

In one embodiment, component (iii) is in form of one or more plasticizers selected from the group consisting of carbonates, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, compounds with a structure similar to lignin like vanillin, acetosyringone, solvents used as coalescing agents like alcohol ethers, polyvinyl alcohol.

In one embodiment, component (iii) is in form of one or more non-reactive plasticizer selected from the group consisting of polyethylene glycols, polyethylene glycol ethers, polyethers, hydrogenated sugars, phthalates and/or other esters, solvents used as coalescing agents like alcohol ethers, acrylic polymers, polyvinyl alcohol.

In one embodiment, component (iii) is one or more reactive plasticizers selected from the group consisting of carbonates, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, di- or tricarboxylic acids, such as adipic acid, or lactic acid, and/or vanillic acid and/or ferullic acid, polyurethane dispersions, acrylic based polymers with free carboxy groups, compounds with a structure similar to lignin like vanillin, acetosyringone.

In one embodiment, component (iii) is in form of one or more plasticizers selected from the group consisting of fatty alcohols, monohydroxy alcohols such as pentanol, stearyl alcohol.

In one embodiment, component (iii) comprises one or more plasticizers selected from the group consisting of polyethylene glycols, polyethylene glycol ethers, and/or one or more plasticizers in form of polyols, such as 1,1,1-Tris(hydroxymethyl)propane, and/or triethanolamine.

Another particular surprising aspect of the present invention is that the use of plasticizers having a boiling point of more than 100° C., in particular 140 to 250° C., strongly improves the mechanical properties of the mineral fibre products according to the present invention although, in view of their boiling point, it is likely that these plasticizers will at least in part evaporate during the curing of the binders in contact with the mineral fibres.

In one embodiment, component (iii) comprises one or more plasticizers having a boiling point of more than 100° C., such as 110 to 380° C., more preferred 120 to 300° C., more preferred 140 to 250° C.

It is believed that the effectiveness of these plasticizers in the binder composition according to the present invention is associated with the effect of increasing the mobility of the lignins during the curing process. It is believed that the increased mobility of the lignins during the curing process facilitates the effective crosslinking.

In one embodiment, component (iii) comprises one or more polyethylene glycols having an average molecular weight of 150 to 50000 g/mol, in particular 150 to 4000 g/mol, more particular 150 to 1000 g/mol, preferably 150 to 500 g/mol, more preferably 200 to 400 g/mol.

In one embodiment, component (iii) comprises one or more polyethylene glycols having an average molecular weight of 4000 to 25000 g/mol, in particular 4000 to 15000 g/mol, more particular 8000 to 12000 g/mol.

In one embodiment component (iii) is capable of forming covalent bonds with component (i) and/or component (ii) during the curing process. Such a component would not evaporate and remain as part of the composition but will be effectively altered to not introduce unwanted side effects e.g. water absorption in the cured product. Non-limiting examples of such a component are caprolactone and acrylic based polymers with free carboxyl groups.

In one embodiment, component (iii) is selected from the group consisting of fatty alcohols, monohydroxy alcohols, such as pentanol, stearyl alcohol.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of alkoxylates such as ethoxylates such as butanol ethoxylates, such as butoxytriglycol.

In one embodiment, component (iii) is selected from one or more propylene glycols.

In one embodiment, component (iii) is selected from one or more glycol esters.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of adipates, acetates, benzoates, cyclobenzoates, citrates, stearates, sorbates, sebacates, azelates, butyrates, valerates.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of phenol derivatives such as alkyl or aryl substituted phenols.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of silanols, siloxanes.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of sulfates such as alkyl sulfates, sulfonates such as alkyl aryl sulfonates such as alkyl sulfonates, phosphates such as tripolyphosphates; such as tributylphosphates.

In one embodiment, component (iii) is selected from one or more hydroxy acids.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of monomeric amides such as acetamides, benzamide, fatty acid amides such as tall oil amides.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of quaternary ammonium compounds such as trimethylglycine, distearyldimethylammoniumchloride.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of vegetable oils such as castor oil, palm oil, linseed oil, tall oil, soybean oil.

In one embodiment, component (iii) is in form of tall oil.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of hydrogenated oils, acetylated oils.

In one embodiment, component (iii) is selected from one or more fatty acid methyl esters.

In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of alkyl polyglucosides, gluconamides, aminoglucoseamides, sucrose esters, sorbitan esters.

In one embodiment, component (iii) is selected from the group consisting of polyethylene glycols, polyethylene glycol ethers.

In one embodiment, component (iii) is selected from the group consisting of triethanolamine.

In one embodiment, component (iii) is in form of propylene glycols, phenol derivatives, silanols, siloxanes, hydroxy acids, vegetable oils, polyethylene glycols, polyethylene glycol ethers, and/or one or more plasticizers in form of polyols, such as 1,1,1-Tris(hydroxymethyl)propane, triethanolamine, or any mixtures thereof.

It has surprisingly been found that the inclusion of plasticizers in the binder compositions according to the present invention strongly improves the mechanical properties of the mineral fibre products according to the present invention.

The term plasticizer refers to a substance that is added to a material in order to make the material softer, more flexible (by decreasing the glass-transition temperature Tg) and easier to process.

Component (iii) can also be any mixture of the above mentioned compounds.

In one embodiment, component (iii) is present in an amount of 0.5 to 60, preferably 2.5 to 25, more preferably 3 to 15 wt.-%, based on the dry weight of component (i).

In one embodiment, component (iii) is present in an amount of 0.5 to 60, preferably 2.5 to 25, more preferably 3 to 15 wt.-%, based on the dry weight of components (i), (ii), and (iii).

Mineral Fibre Product Comprising Mineral Fibres in Contact With a Binder Resulting From the Curing of a Binder Composition Comprising Components (I) and (IIa)

In one embodiment the present invention is directed to a mineral fibre product comprising mineral fibres in contact with a binder resulting from the curing of a binder composition for mineral fibres comprising:

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins. -   a component (iia) in form of one or more modifiers, preferably with     the proviso that the aqueous binder composition does not comprise a     cross-linker selected from     -   epoxy compounds having a molecular weight Mw of 500 or less,         and/or with the proviso that the aqueous binder composition does         not comprise a cross-linker selected from     -   carbonyl compounds selected from aldehydes, carbonyl compounds         of the formula R—[C(O)R₁]_(x) in which:         -   R represents a saturated or unsaturated and linear, branched             or cyclic hydrocarbon radical, a radical including one or             more aromatic nuclei which consist of 5 or 6 carbon atoms, a             radical including one or more aromatic heterocycles             containing 4 or 5 carbon atoms and an oxygen, nitrogen or             sulfur atom, it being possible for the R radical to contain             other functional groups,         -   R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and         -   x varies from 1 to 10, -   and/or with the proviso that the aqueous binder composition does not     comprise a cross-linker selected from     -   polyamines, and/or with the proviso that the aqueous binder         composition does not comprise a cross-linker selected from     -   mono- and oligosaccharides.

The present inventors have found that the excellent binder properties can also be achieved by a two-component system which comprises component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins and a component (iia) in form of one or more modifiers, and optionally any of the other components mentioned above and below.

In one embodiment, component (iia) is a modifier in form of one or more compounds selected from the group consisting of epoxy compounds having a molecular weight of more than 500, such as an epoxidised oil based on fatty acid triglyceride or one or more flexible oligomer or polymer, such as a low Tg acrylic based polymer, such as a low Tg vinyl based polymer, such as low Tg polyether, which contains reactive functional groups such as carbodiimide groups, such as anhydride groups, such as oxazoline groups, such as amino groups, such as epoxy groups such as β-hydroxyalkylamide groups.

In one embodiment, component (iia) is one or more modifiers selected from the group consisting of polyethylene imine, polyvinyl amine, fatty amines.

In one embodiment, the component (iia) is one or more modifiers selected from multifunctional carbodiimides, such as aliphatic multifunctional carbodiimides.

Component (iia) can also be any mixture of the above mentioned compounds.

Without wanting to be bound by any particular theory, the present inventors believe that the excellent binder properties achieved by the binder composition for mineral fibres comprising components (i) and (iia), and optional further components, are at least partly due to the effect that the modifiers used as components (iia) at least partly serve the function of a plasticizer and a cross-linker.

In one embodiment, the binder composition comprises component (iia) in an amount of 1 to 40 wt.-%, such as 4 to 20 wt.-%, such as 6 to 12 wt.-%, based on the dry weight of the component (i).

Further Components

In some embodiments, the mineral fibre product according to the present invention comprises mineral fibres in contact with a binder composition resulting from the curing of a binder which comprises further components.

In one embodiment, the binder composition comprises a catalyst selected from inorganic acids, such as sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and/or phosphoric acid, and/or any salts thereof such as sodium hypophosphite, and/or ammonium salts, such as ammonium salts of sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and/or phosphoric acid, and/or sodium polyphosphate (STTP), and/or sodium metaphosphate (STMP), and/or phosphorous oxychloride. The presence of such a catalyst can improve the curing properties of the binder compositions according to the present invention.

In one embodiment, the binder composition comprises a catalyst selected from Lewis acids, which can accept an electron pair from a donor compound forming a Lewis adduct, such as ZnCl₂, Mg (ClO₄)₂, Sn [N(SO₂-n-C₈F₁₇)₂]₄.

In one embodiment, the binder composition comprises a catalyst selected from metal chlorides, such as KCl, MgCl₂, ZnCl₂, FeCl₃ and SnCl₂or their adducts such as AlCl₃ adducts, such as BF₃ adducts, such as BF₃ ethylamine complex.

In one embodiment, the binder composition comprises a catalyst selected from organometallic compounds, such as titanate-based catalysts and stannum based catalysts.

In one embodiment, the binder composition comprises a catalyst selected from chelating agents, such as transition metals, such as iron ions, chromium ions, manganese ions, copper ions and/or from peroxides such as organic peroxides such as dicumyl peroxide.

In one embodiment, the binder composition according to the present invention comprises a catalyst selected from phosphites such as alkyl phosphites, such as aryl phosphites such as triphenyl phosphite.

In one embodiment, the binder composition according to the present invention comprises a catalyst selected from the group of ternary amines such as tris-2,4,6-dimethylaminomethyl phenol.

In one embodiment, the binder composition further comprises a further component (iv) in form of one or more silanes.

In one embodiment, the binder composition comprises a further component (iv) in form of one or more coupling agents, such as organofunctional silanes.

In one embodiment, component (iv) is selected from group consisting of organofunctional silanes, such as primary or secondary amino functionalized silanes, epoxy functionalized silanes, such as polymeric or oligomeric epoxy functionalized silanes, methacrylate functionalized silanes, alkyl and aryl functionalized silanes, urea funtionalised silanes or vinyl functionalized silanes.

In one embodiment, the binder composition further comprises a component (v) in form of one or more components selected from the group of bases, such as ammonia, such as alkali metal hydroxides, such as KOH, such as earth alkaline metal hydroxides, such as Ca(OH)₂, such as Mg(OH)₂, such as amines or any salts thereof.

In one embodiment, the binder composition further comprises a further component in form of urea, in particular in an amount of 5 to 40 wt.-%, such as 10 to 30 wt.-%, 15 to 25 wt.-%, based on the dry weight of component (i).

In one embodiment, the binder composition further comprises a further component in form of one or more carbohydrates selected from the group consisting of sucrose, reducing sugars, in particular dextrose, polycarbohydrates, and mixtures thereof, preferably dextrins and maltodextrins, more preferably glucose syrups, and more preferably glucose syrups with a dextrose equivalent value of DE = 30 to less than 100, such as DE = 60 to less than 100, such as DE = 60-99, such as DE = 85-99, such as DE = 95-99.

In one embodiment, the binder composition further comprises a further component in form of one or more carbohydrates selected from the group consisting of sucrose and reducing sugars in an amount of 5 to 50 wt.-%, such as 5 to less than 50 wt.-%, such as 10 to 40 wt.-%, such as 15 to 30 wt.-% based on the dry weight of component (i).

In one embodiment, the mineral fibre product according to the present invention comprises mineral fibres in contact with the binder composition comprising a further component in form of one or more silicone resins.

In one embodiment, the binder composition according to the present invention comprises a further component (vi) in the form of one or more reactive or nonreactive silicones.

In one embodiment, the component (vi) is selected from the group consisting of silicone constituted of a main chain composed of organosiloxane residues, especially diphenylsiloxane residues, alkylsiloxane residues, preferably dimethylsiloxane residues, bearing at least one hydroxyl, carboxyl or anhydride, amine, epoxy or vinyl functional group capable of reacting with at least one of the constituents of the binder composition and is preferably present in an amount of 0.025-15 weight-%, preferably from 0.1-10 weight-%, more preferably 0.3-8 weight-%, based on the binder solids.

In one embodiment, the mineral fibre product according to the present invention comprises mineral fibres in contact with the binder composition comprising a further component in form of one or more mineral oils.

In the context of the present invention, a binder composition having a sugar content of 50 wt.-% or more, based on the total dry weight of the binder components, is considered to be a sugar based binder. In the context of the present invention, a binder composition having a sugar content of less than 50 wt.-%, based on the total dry weight of the binder components, is considered a non-sugar based binder.

In one embodiment, the binder composition further comprises a further component in form of one or more surface active agents that are in the form of non-ionic and/or ionic emulsifiers such as polyoxyethylenes (4) lauryl ether, such as soy lecithin, such as sodium dodecyl sulfate.

The use of lignin-based sulfonated products in binders may result in an increase in the hydrophilicity of some binders and final products, meaning one or more hydrophobic agents are to be added, such as one or more mineral oils, such as one or more silicone oil, such as one or more silicone resin.

In one embodiment, the aqueous binder composition consists essentially of

-   a component (i) in form of one or more lignins selected from the     group of:     -   lignosulfonate lignins having a carboxylic acid group content of         0.03 to 2.0 mmol/g, such as 0.03 to 1.4 mmol/g, such as 0.075 to         2.0 mmol/g, such as 0.075 to 1.4 mmol/g, based on the dry weight         of the lignosulfonate lignins, and/or -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers; -   a component (iv) in form of one or more coupling agents, such as     organofunctional silanes; -   optionally a component in form of one or more compounds selected     from the group of bases, such as ammonia, such as alkali metal     hydroxides, such as KOH, such as earth alkaline metal hydroxides,     such as Ca(OH)₂, such as Mg(OH)₂, such as amines or any salts     thereof; -   optionally a component in form of urea; -   optionally a component in form of a more reactive or non-reactive     silicones; -   optionally a hydrocarbon oil; -   optionally one or more surface active agents; -   water.

The present inventors have surprisingly found that mineral fiber products comprising mineral fibers in contact with a binder resulting in the curing of an aqueous binder composition as it is described above have at a very high stability, both when freshly produced and after aging conditions.

Further, the present inventors have found that even higher product stability can be obtained by using a curing temperature of >230° C.

In one embodiment, the present invention is therefore directed to a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of an aqueous binder composition as it is described above, where the curing temperature of >230° C. is used.

The present inventors have further found that the stability of the mineral fiber product can be further increased by the following measures:

-   Lower line capacity, meaning longer curing time -   Addition of silicone resins -   Addition of high amounts of crosslinker -   Addition of a combination of two or more different crosslinkers -   Addition of small amounts of cationic species such as multivalent     metal ions such as calcium and/or organic cationic species such as     amines and/or organically modified inorganic compounds such as amine     modified montmorillonite clays

A Method for Producing a Mineral Fibre Product

The present invention also provides a method for producing a mineral fibre product by binding mineral fibres with the binder composition.

Accordingly, the present invention is also directed to a method for producing a mineral fibre product which comprises the steps of contacting mineral fibres with a binder composition comprising

-   a component (i) in form of one or more lignosulfonate lignins having     a carboxylic acid group content of 0.03 to 2.0 mmol/g, such as 0.03     to 1.4 mmol/g, such as 0.075 to 2.0 mmol/g, such as 0.075 to 1.4     mmol/g, based on the dry weight of the lignosulfonate lignins; -   a component (ii) in form of one or more cross-linkers; -   a component (iii) in form of one or more plasticizers,

preferably with the proviso that the aqueous binder composition does not comprise a cross-linker selected from

-   epoxy compounds having a molecular weight Mw of 500 or less and/or -   with the proviso that the aqueous binder composition does not     comprise a cross-linker selected from -   carbonyl compounds selected from aldehydes, carbonyl compounds of     the formula R—[C(O)R₁]_(x)     -   in which:     -   R represents a saturated or unsaturated and linear, branched or         cyclic hydrocarbon radical, a radical including one or more         aromatic nuclei which consist of 5 or 6 carbon atoms, a radical         including one or more aromatic heterocycles containing 4 or 5         carbon atoms and an oxygen, nitrogen or sulfur atom, it being         possible for the R radical to contain other functional groups,     -   R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and x         varies from 1 to 10 -   and/or -   with the proviso that the aqueous binder composition does not     comprise a cross-linker selected from -   polyamines -   and/or -   with the proviso that the aqueous binder composition does not     comprise a cross-linker selected from -   mono- and oligosaccharides.

Curing

The web is cured by a chemical and/or physical reaction of the binder components.

In one embodiment, the curing takes place in a curing device.

In one embodiment, the curing is carried out at temperatures from 100 to 300° C., such as 170 to 270° C., such as 180 to 250° C., such as 190 to 230° C.

In one embodiment, the curing takes place in a conventional curing oven for mineral wool production operating at a temperature of from 150 to 300° C., such as 170 to 270° C., such as 180 to 250° C., such as 190 to 230° C.

In one embodiment, the curing takes place for a time of 30 seconds to 20 minutes, such as 1 to 15 minutes, such as 2 to 10 minutes.

In a typical embodiment, curing takes place at a temperature of 150 to 250° C. for a time of 30 seconds to 20 minutes.

The curing process may commence immediately after application of the binder to the fibres. The curing is defined as a process whereby the binder composition undergoes a physical and/or chemical reaction which in case of a chemical reaction usually increases the molecular weight of the compounds in the binder composition and thereby increases the viscosity of the binder composition, usually until the binder composition reaches a solid state.

In a one embodiment, the curing of the binder in contact with the mineral fibres takes place in a heat press.

The curing of a binder in contact with the mineral fibres in a heat press has the particular advantage that it enables the production of high-density products.

In one embodiment the curing process comprises drying by pressure. The pressure may be applied by blowing air or gas through/over the mixture of mineral fibres and binder.

Mineral Fibre Product

The present invention is directed to a mineral fibre product comprising mineral fibres in contact with a cured binder composition resulting from the curing of the aqueous binder composition.

The mineral fibres employed may be any of man-made vitreous fibres (MMVF), glass fibres, ceramic fibres, basalt fibres, slag fibres, rock fibres, stone fibres and others. These fibres may be present as a wool product, e.g. like a stone wool product.

Fibre/Melt Composition

The man-made vitreous fibres (MMVF) can have any suitable oxide composition. The fibres can be glass fibres, ceramic fibres, basalt fibres, slag fibres or rock or stone fibres. The fibres are preferably of the types generally known as rock, stone or slag fibres, most preferably stone fibres.

Stone fibres commonly comprise the following oxides, in percent by weight:

-   SiO₂: 30 to 51 -   CaO: 8 to 30 -   MgO: 2 to 25 -   FeO (including Fe₂O₃): 2 to 15 -   Na₂O+K₂O: not more than 10 -   CaO+MgO: 10 to 30

In preferred embodiments the MMVF have the following levels of elements, calculated as oxides in wt%:

-   SiOz: at least 30, 32, 35 or 37; not more than 51, 48, 45 or 43 -   Al₂O₃: at least 12, 16 or 17; not more than 30, 27 or 25 -   CaO: at least 8 or 10; not more than 30, 25 or 20 -   MgO: at least 2 or 5; not more than 25, 20 or 15 -   FeO (including Fe₂O₃): at least 4 or 5; not more than 15, 12 or 10 -   FeO+MgO: at least 10, 12 or 15; not more than 30, 25 or 20 -   Na₂O+K₂O: zero or at least 1; not more than 10 -   CaO+MgO: at least 10 or 15; not more than 30 or 25 -   TiO2: zero or at least 1; not more than 6, 4 or 2 -   TiO₂+FeO: at least 4 or 6; not more than 18 or 12 -   B₂O₃: zero or at least 1; not more than 5 or 3 -   P₂O₅: zero or at least 1; not more than 8 or 5 -   Others: zero or at least 1; not more than 8 or 5

The MMVF made by the method of the invention preferably have the composition in wt.-%:

-   SiO₂ 35 to 50 -   Al₂O₃ 12 to 30 -   TiO₂ up to 2 -   Fe₂O₃ 3 to 12 -   CaO 5 to 30 -   MgO up to 15 -   Na₂O 0 to 15 -   K2O 0 to 15 -   P₂O₅ up to 3 -   MnO up to 3 -   B₂O₃ up to 3

Another preferred composition for the MMVF is as follows in wt%:

-   SiO₂ 39-55% preferably 39-52% -   Al₂O₃ 16-27% preferably 16-26% -   CaO 6-20% preferably 8-18% -   MgO 1-5% preferably 1-4.9% -   Na₂O 0-15% preferably 2-12% -   K₂O 0-15% preferably 2-12% -   R₂O (Na₂O + K₂O) 10-14.7% preferably 10-13.5% -   P₂O₅ 0-3% preferably 0-2% -   Fe₂O₃ (iron total) 3-15% preferably 3.2-8% -   B₂O₃ 0-2% preferably 0-1% -   TiO₂ 0-2% preferably 0.4-1% -   Others 0-2.0%

Glass fibres commonly comprise the following oxides, in percent by weight:

-   SiO₂: 50 to 70 -   Al₂O₃: 10 to 30 -   CaO: not more than 27 -   MgO: not more than 12

Glass fibres can also contain the following oxides, in percent by weight: Na₂O+K₂O: 8 to 18, in particular Na₂O+K₂O greater than CaO+MgO B₂O₃: 3 to 12

Some glass fibre compositions can contain Al₂O₃: less than 2%.

Suitable fibre formation methods and subsequent production steps for manufacturing the mineral fibre product are those conventional in the art. Generally, the binder is sprayed immediately after fibrillation of the mineral melt on to the airborne mineral fibres. The aqueous binder composition is normally applied in an amount of 0.1 to 18%, preferably 0.2 to 8 % by weight, of the bonded mineral fibre product on a dry basis.

The spray-coated mineral fibre web is generally cured in a curing oven by means of a hot air stream. The hot air stream may be introduced into the mineral fibre web from below, or above or from alternating directions in distinctive zones in the length direction of the curing oven.

Typically, the curing oven is operated at a temperature of from about 100° C. to about 300° C., such as 170 to 270° C., such as 180 to 250° C., such as 190 to 230° C. Generally, the curing oven residence time is from 30 seconds to 20 minutes, such as 1 to 15 minutes, such as 2 to 10 minutes, depending on, for instance, the product density.

In a typical embodiment, the mineral fibre product according to the present invention is cured at a temperature of 150° C. to 250° C. for a time of 30 seconds to 20 minutes.

If desired, the mineral wool web may be subjected to a shaping process before curing. The bonded mineral fibre product emerging from the curing oven may be cut to a desired format e.g., in the form of a batt. Thus, the mineral fibre products produced, for instance, have the form of woven and nonwoven fabrics, mats, batts, slabs, sheets, plates, strips, rolls, granulates and other shaped articles which find use, for example, as thermal or acoustical insulation materials, vibration damping, construction materials, facade insulation, reinforcing materials for roofing or flooring applications, as filter stock and in other applications.

In accordance with the present invention, it is also possible to produce composite materials by combining the bonded mineral fibre product with suitable composite layers or laminate layers such as, e.g., metal, glass surfacing mats and other woven or non-woven materials.

The mineral fibre products according to the present invention generally have a density within the range of from 6 to 250 kg/m³, preferably 20 to 200 kg/m³. The mineral fibre products generally have a loss on ignition (LOI) within the range of 0.3 to 18.0 %, preferably 0.5 to 8.0 %.

Use of a Lignin Component For The Preparation of a Binder Composition

The present invention is also directed to the use of a lignin component in form of one or more lignosulfonate lignins having the features as described above for component (i) for the preparation of a binder composition for mineral wool.

In one embodiment, the binder composition is free of phenol and formaldehyde.

In one embodiment, the present invention is directed to the use of a lignin component in the form of one or more lignosulfonate lignins having the features of component (i) described above for the preparation of a binder composition, preferably free of phenol and formaldehyde, for mineral wool, whereby this binder composition further comprises components (ii) and (iii) as defined above, preferably with the proviso that the aqueous binder composition does not comprise a cross-linker selected from

-   epoxy compounds having a molecular weight Mw of 500 or less and/or -   with the proviso that the aqueous binder composition does not     comprise a cross-linker selected from -   carbonyl compounds selected from aldehydes, carbonyl compounds of     the formula R—[C(O)R₁]_(x) in which:     -   R represents a saturated or unsaturated and linear, branched or         cyclic hydrocarbon radical, a radical including one or more         aromatic nuclei which consist of 5 or 6 carbon atoms, a radical         including one or more aromatic heterocycles containing 4 or 5         carbon atoms and an oxygen, nitrogen or sulfur atom, it being         possible for the R radical to contain other functional groups,     -   R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and     -   x varies from 1 to 10 -   and/or -   with the proviso that the aqueous binder composition does not     comprise a cross-linker selected from -   polyamines -   and/or -   with the proviso that the aqueous binder composition does not     comprise a cross-linker selected from -   mono- and oligosaccharides.

In one embodiment, the present invention is directed to the use of a lignin component in form of one or more lignosulfonate lignins having the features of component (i) described above for the preparation of a binder composition, preferably free of phenol and formaldehyde, whereby the binder composition further comprises component (iia) as defined above.

Examples

In the following examples, several binders which fall under the definition of the present invention were prepared and compared to binders according to the prior art.

The following properties were determined for the binders according to the present invention and the binders according to the prior art, respectively:

Binder Component Solids Content

The content of each of the components in a given binder solution before curing is based on the anhydrous mass of the components.

Lignosulfonates were supplied by Borregaard, Norway and LignoTech, Florida as liquids with approximately 50 % solid content. Primid XL552 was supplied by EMS-CHEMIE AG, Silane (Momentive VS-142 40% activity), was supplied by Momentive and was calculated as 100% for simplicity. NH4OH 24.7% was supplied by Univar and used in supplied form. PEG 200, urea, KOH pellets, 1,1,1 tris(hydroxymethyl)propane were supplied by Sigma-Aldrich and were assumed anhydrous for simplicity.

Binder Solids

The content of binder after curing is termed “binder solids”.

Disc-shaped stone wool samples (diameter: 5 cm; height 1 cm) were cut out of stone wool and heat-treated at 580° C. for at least 30 minutes to remove all organics. The solids of the binder mixture was measured by distributing a sample of the binder mixture (approx. 2 g) onto a heat treated stone wool disc in a tin foil container. The weight of the tin foil container containing the stone wool disc was weighed before and directly after addition of the binder mixture. Two such binder mixture loaded stone wool discs in tin foil containers were produced and they were then heated at 200° C. for 1 hour. After cooling and storing at room temperature for 10 minutes, the samples were weighed and the binder solids was calculated as an average of the two results.

A binder with a desired binder solids could then be produced by diluting with the required amount of water and 10% aq. silane (Momentive VS-142).

Mechanical Strength Studies Bar Tests

The mechanical strength of the binders was tested in a bar test. For each binder, 16 bars were manufactured from a mixture of the binder and stone wool shots from the stone wool spinning production.

A sample of this binder solution having 15% dry solid matter (16.0 g) was mixed well with shots (80.0 g). The resulting mixture was then filled into four slots in a heat resistant silicone form for making small bars (4×5 slots per form; slot top dimension: length = 5.6 cm, width = 2.5 cm; slot bottom dimension: length = 5.3 cm, width = 2.2 cm; slot height = 1.1 cm). The mixtures placed in the slots were then pressed with a suitably sized flat metal bar to generate even bar surfaces. 16 bars from each binder were made in this fashion. The resulting bars were then cured typically at 225° C. The curing time was 1 h. After cooling to room temperature, the bars were carefully taken out of the containers. Five of the bars were aged in a water bath at 80° C. for 3 h. This method of curing the prepared bars was used for examples in tables 1.1, 1.2, 1.4, 1.5, 1.6. Results in Table 1.3 are based on a slightly different method which includes a preconditioning step of 2 h at 90° C., followed by curing for 1 h at 225° C. while the remaining of the procedure is the same.

After drying for 3 days, the aged bars as well as five unaged bars were broken in a 3 point bending test (test speed: 10.0 mm/min; rupture level: 50%; nominal strength: 30 N/mm²; support distance: 40 mm; max deflection 20 mm; nominal e-module 10000 N/mm²) on a Bent Tram machine to investigate their mechanical strengths. The bars were placed with the “top face” up (i.e. the face with the dimensions length = 5.6 cm, width = 2.5 cm) in the machine.

Binder Example, Reference Binder (Phenol-Formaldehyde Resin Modified with Urea, a PUF-Resol)

This binder is a phenol-formaldehyde resin modified with urea, a PUF-resol.

A phenol-formaldehyde resin is prepared by reacting 37% aq. formaldehyde (606 g) and phenol (189 g) in the presence of 46% aq. potassium hydroxide (25.5 g) at a reaction temperature of 84° C. preceded by a heating rate of approximately 1° C. per minute. The reaction is continued at 84° C. until the acid tolerance of the resin is 4 and most of the phenol is converted. Urea (241 g) is then added and the mixture is cooled.

The acid tolerance (AT) expresses the number of times a given volume of a binder can be diluted with acid without the mixture becoming cloudy (the binder precipitates). Sulfuric acid is used to determine the stop criterion in a binder production and an acid tolerance lower than 4 indicates the end of the binder reaction.

To measure the AT, a titrant is produced from diluting 2.5 ml conc. sulfuric acid (>99 %) with 1 L ion exchanged water. 5 mL of the binder to be investigated is then titrated at room temperature with this titrant while keeping the binder in motion by manually shaking it; if preferred, use a magnetic stirrer and a magnetic stick. Titration is continued until a slight cloud appears in the binder, which does not disappear when the binder is shaken.

The acid tolerance (AT) is calculated by dividing the amount of acid used for the titration (mL) with the amount of sample (mL):

AT = (Used titration volume(mL))/(Sample volume(mL))

Using the urea-modified phenol-formaldehyde resin obtained, a binder is made by addition of 25% aq. ammonia (90 mL) and ammonium sulfate (13.2 g) followed by water (1.30 kg).

The binder solids were then measured as described above and the mixture was diluted with the required amount of water and silane for mechanical measurements (15 % binder solids solution, 0.5% silane of binder solids).

Binder Example, Reference Binder (Binder Based on Alkali Oxidized Lignin)

3267 kg of water is charged in 6000 l reactor followed by 287 kg of ammonia water (24.7%). Then 1531 kg of Lignin UPM BioPiva 100 is slowly added over a period of 30 min to 45 min. The mixture is heated to 40° C. and kept at that temperature for 1 hour. After 1 hour a check is made on insolubilized lignin. This can be made by checking the solution on a glass plate or a Hegman gauge. Insolubilized lignin is seen as small particles in the brown binder. During the dissolution step will the lignin solution change color from brown to shiny black. After the lignin is completely dissolved, 1 liter of a foam dampening agent (Skumdaemper 11-10 from

NCA-Verodan) is added. Temperature of the batch is maintained at 40° C. Then addition of 307.5 kg 35% hydrogen peroxide is started. The hydrogen peroxide is dosed at a rate of 200-300 l/h. First half of the hydrogen peroxide is added at a rate of 200 l/h where after the dosage rate is increased to 300 l/h.

During the addition of hydrogen peroxide is the temperature in the reaction mixture controlled by heating or cooling in such a way that a final reaction temperature of 65° C. is reached.

The final product was analysed for the COOH group content, dry solid matter, pH, viscosity and remaining H₂O₂.60 g of this oxidized lignin (18.2 % solids) was mixed with 1.4 g Primid XL552 (100 % solids) and 2.8 g PEG200 (100 % solids). 0.6 g Silane (Momentive VS-142 40% activity, 10% in water) and 17.4 g water were added and mixed to yield 15 % solids and then used for test of mechanical properties in bar tests.

Binder Compositions According to the Present Invention

In the following, the entry numbers of the binder example correspond to the entry numbers used in Table 1-1 to 1-6.

The carboxylic acid group content of all lignosulfonates used for the binders according to the present invention was measured using ³¹P NMR and was found to be in the range of 0.05 to 0.6 mmol/g, based on the dry weight of the lignosulfonate lignins, for all examples.

Example 2

To 30.0 g lignosulfonate solution (50 % solids), 0.4 g NH4OH (24.7 %) was added and mixed followed by addition of 1.9 g Primid XL552 (100 % solids) and mixing. Finally, 0.7 g Silane (Momentive VS-142 40% activity, 10% in water) and 64.3 g water were added and mixed to yield 15 % solids and then used for test of mechanical properties in bar tests.

Example 11

To 30.0 g lignosulfonate solution (50 % solids), 0.4 g NH4OH (24.7 %) was added and mixed followed by addition of 2.1 g Primid XL552 (100 % solids) and 3.4 g PEG 200 (100 % solids) and mixing. Finally, 0.7 g Silane (Momentive VS-142 40% activity, 10% in water) and 61.8 g water were added and mixed to yield 15 % solids and then used for test of mechanical properties in bar tests.

Example 15

To 30.0 g lignosulfonate solution (50 % solids), 0.4 g NH4OH (24.7 %) was added and mixed followed by addition of 2.9 g Primid XL552 (100 % solids) and 3.4 g PEG 200 (100 % solids) and mixing. Finally, 0.8 g Silane (Momentive VS-142 40% activity, 10% in water) and 67 g water were added and mixed to yield 15 % solids and then used for test of mechanical properties in bar tests.

Example 30

To 30.0 g lignosulfonate solution (50 % solids), 0.4 g NH₄OH (24.7 %) was added and mixed followed by addition of 2.9 g Primid XL552 (100 % solids) and 3.4 g 1,1,1 tris(hydroxymethyl)propane (100 % solids) and mixing. Finally, 0.8 g Silane (Momentive VS-142 40% activity, 10% in water) and 67 g water were added and mixed to yield 15 % solids and then used for test of mechanical properties in bar tests.

Example 33

To 100.0 g lignosulfonate solution (50 % solids), 0.3 g KOH in pellet form was added and mixed followed by addition of 10.8 g Primid XL552 (100 % solids) and 11.3 g PEG 200 (100 % solids) and mixing. Finally, 2.6 g Silane (Momentive VS-142 40% activity, 10% in water) and 228 g water were added and mixed to yield 15 % solids and then used for test of mechanical properties in bar tests.

Example 41

To 30.0 g lignosulfonate solution (50 % solids), 0.4 g NH4OH (24.7 %) was added and mixed followed by addition of 1.9 g Primid XL552 (100 % solids) and 1.7 g PEG 200 (100 % solids) and 1.7 g urea (100 % solids) and mixing. Finally, 0.7 g Silane

(Momentive VS-142 40% activity, 10% in water) and 60.5 g water were added and mixed to yield 15 % solids and then used for test of mechanical properties in bar tests.

Mechanical properties are presented in tables 1.1-1.6. For simplicity, quantities of all other components are recalculated based on 100 g of dry lignin.

As can be seen from Table 1.1 a combination of crosslinker (Primid XL 552) and plasticizer (PEG 200) is required to achieve high mechanical properties (unaged and aged strength in bar test) that are at comparable level to reference binder (11 and 15 versus 2 and 9 versus reference binder).

Table 1.2 and 1.3 show that different plasticizers can be used (13 and 15 versus 30) or combination of plasticizers (34 versus 41) and that the PEG 200 is a preferred plasticizer.

Table 1.4 shows that addition of silane can help achieve aged strength on the same level as reference binders.

Table 1.5 shows that the binder has high strength without the presence of a base but that a non-permanent base (NH₄OH) or a permanent base (KOH) can be added to the formulation to protect the production equipment from corrosion without significant changes in strength.

Table 1.6 shows that different lignosulfonates can be used.

This overall means, we are able to produce a mineral wool product based on a phenol and formaldehyde-free binder composition with a high content of renewable material based on lignin, which has comparable mechanical properties to the reference systems and can be produced in a simpler and less expensive way.

TABLE 1.1 Binder composition Reference binder (Phenol-formaldehyde resin modified with urea, a PUF-resol) Reference binder (binder based on alkali oxidized lignin) 1 2 8 9 10 11 15 ammonium lignosulfonate (g dry lignin) 100 100 100 100 100 100 100 ammonium calcium lignosulfonate (g dry lignin) PEG 200 (g) 0 0 23 40 23 23 23 1,1,1 tris(hydroxymethyl)propane (g) urea (g) NH4OH (g) 0.8 0.8 0.8 0.8 0.8 0.8 0.8 KOH (g) Primid XL552 (g) 0 14 0 0 7 14 20 Momentive VS 142 (% of binder solids), based on 40% activity 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Binder properties Mechanical strength, unaged (N), bars tests 350 270 60 280 70 150 110 230 320 Mechanical strength, aged (N), bar tests 150 130 0 50 20 40 50 140 130 Curing temp, °C 200 225 225 225 225 225 225 225 225

TABLE 1.2 Binder composition 12 13 15 26 27 28 29 30 ammonium lignosulfonate (g dry lignin) 100 100 100 100 100 100 100 100 ammonium calcium lignosulfonate (g dry lignin) PEG 200 (g) 23 23 23 1,1,1 tris(hydroxymethyl)propane (g) 23 23 40 23 23 urea (g) Primid XL552 (g) 13 13 20 0 0 0 20 20 NH4OH (g) 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 KOH (g) Momentive VS 142 (% of binder solids), based on 40% activity 0 0.5 0.5 0 0.5 0.5 0 0.5 Binder properties Mechanical strength, unaged (N), bars tests 250 250 320 80 90 90 200 210 Mechanical strength, aged (N), bar tests 30 110 130 10 10 20 60 100 Curing temp, °C 225 225 225 225 225 225 225 225

TABLE 1.3 Binder composition 34 36 39 40 41 ammonium lignosulfonate (g dry lignin) 100 100 100 100 100 ammonium calcium lignosulfonate (g dry lignin) PEG 200 (g) 23 12 4.5 0 12 1,1,1 tris(hydroxymethyl)propane (g) urea (g) 12 Primid XL552 (g) 13 13 13 13 13 NH4OH (g) 0.8 0.8 0.8 0.8 0.8 KOH (g) Momentive VS 142 (% of binder solids), based on 40% activity 0.5 0.5 0.5 0.5 0.5 Binder properties Mechanical strength, unaged (N), bars tests 150 150 140 60 135 Mechanical strength, aged (N), bar tests 60 50 40 20 40 Curing temp, °C 225 225 225 225 225

TABLE 1.4 Binder composition 12 13 14 15 29 30 ammonium lignosulfonate (g dry lignin) 100 100 100 100 100 100 ammonium calcium lignosulfonate (g dry lignin) PEG 200 (g) 23 23 23 23 1,1,1 tris(hydroxymethyl)propane (g) 23 23 urea (g) Primid XL552 (g) 13 13 20 20 20 20 NH4OH (g) 0.8 0.8 0.8 0.8 0.8 0.8 KOH (g) Momentive VS 142 (% of binder solids), based on 40% activity 0 0.5 0 0.5 0 0.5 Binder properties Mechanical strength, unaged (N), bars tests 250 250 380 320 200 210 Mechanical strength, aged (N), bar tests 30 110 40 130 60 100 Curing temp, °C 225 225 225 225 225 225

TABLE 1.5 Binder composition 31 32 33 ammonium lignosulfonate (g dry lignin) 100 100 100 ammonium calcium lignosulfonate (g dry lignin) PEG 200 (g) 23 23 23 1,1,1 tris(hydroxymethyl)propane (g) urea (g) Primid XL552 (g) 22 22 22 NH4OH (g) 0 1.0 0 KOH (g) 0 0 0.6 Momentive VS 142 (% of binder solids), based on 40% activity 0.5 0.5 0.5 Binder properties Mechanical strength, unaged (N), bars tests 330 300 290 Mechanical strength, aged (N), bar tests 160 120 130 Curing temp, °C 225 225 225

TABLE 1.6 Binder composition 11 15 45 46 ammonium lignosulfonate (g dry lignin) 100 100 ammonium calcium lignosulfonate (g dry lignin) 100 100 PEG 200 (g) 23 23 23 23 1,1,1 tris(hydroxymethyl)propane (g) urea (g) Primid XL552 (g) 13 20 13 20 NH4OH (g) 0.8 0.8 0.8 0.8 KOH (g) Momentive VS 142 (% of binder solids), based on 40% activity 0.5 0.5 0.5 0.5 Binder properties Mechanical strength, unaged (N), bar tests 230 320 210 300 Mechanical strength, aged (N), bar tests 140 130 120 130 Curing temp, °C 225 225 225 225 

1 –
 23. (canceled)
 24. A mineral fiber product, wherein the product comprises mineral fibers in contact with a binder resulting from curing an aqueous binder composition free of phenol and formaldehyde and comprising: a component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of from 0.03 mmol/g to 1.4 mmol/g, based on a dry weight of the lignosulfonate lignins, a component (ii) in the form of one or more cross-linkers; a component (iii) in the form of one or more plasticizers; provided that the aqueous binder composition does not comprise a cross-linker selected from epoxy compounds having a molecular weight M_(w) of 500 or less; carbonyl compounds selected from aldehydes, carbonyl compounds of the formula R—[C(O)R₁]_(x) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, R₁ represents a hydrogen atom or a C₁-C₁₀ alkyl radical, and x varies from 1 to 10; polyamines.
 25. The mineral fiber product of claim 24, wherein component (i) has a carboxylic acid group content of from 0.05 mmol/g to 0.6 mmol/g, based on the dry weight of lignosulfonate lignins.
 26. The mineral fiber product of claim 24, wherein component (i) is in the form of one or more lignosulfonate lignins having an average carboxylic acid group content of less than 1.8 groups per macromolecule considering an Mn wt. average of component (i).
 27. The mineral fiber product of claim 24, wherein component (i) has a content of phenolic OH groups of from 0.3 mmol/g to 2.5 mmol/g, based on the dry weight of lignosulfonate lignins.
 28. The mineral fiber product of claim 24, wherein component (i) has a content of aliphatic OH groups of from 1.0 mmol/g to 8.0 mmol/g, based on the dry weight of lignosulfonate lignins.
 29. The mineral fiber product of claim 24, wherein component (i) comprises ammoniumlignosulfonates and/or calciumlignosulfonates, and/or magnesiumlignosulfonates, and any combinations thereof.
 30. The mineral fiber product of claim 24, wherein component (i) comprises ammoniumlignosulfonates and calciumlignosulfonates in which a molar ratio of NH₄+ to Ca²⁺ ranges from 5:1 to 1:5.
 31. The mineral fiber product of claim 24, wherein the aqueous binder composition contains added sugar in an amount of from 0 to less than 5 wt.-%, based on a total weight of lignosulfonate and sugar.
 32. The mineral fiber product of claim 24, wherein the aqueous binder composition comprises from 50 wt.-% to 98 wt.-% of component (i), based on a dry weight of components (i) and (ii).
 33. The mineral fiber product of claim 24, wherein component (ii) is in the form of one or more cross-linkers selected from β-hydroxyalkylamide-cross-linkers; and/or oxazoline-cross-linkers; and/or multifunctional organic amines; and/or epoxy compounds having a molecular weight of more than 500 or one or more flexible oligomers or polymers which contain reactive functional groups; and/or one or more cross-linkers selected from fatty amines; and/or one more cross-linkers in the form of fatty amides; and/or one or more cross-linkers selected from polyester polyol; and/or one or more cross-linkers selected from starch, modified starch, carboxymethylcellulose (CMC); and/or one or more cross-linkers in the form of multifunctional carbodiimides; and/or one or more cross-linkers selected from melamine based cross-linkers.
 34. The mineral fiber product of claim 24, wherein component (ii) comprises one or more cross-linkers selected from β-hydroxyalkylamide cross-linkers and/or oxazoline-cross-linkers.
 35. The mineral fiber product of claim 24, wherein the product comprises from 1 wt.-% to 50 wt.-% of component (ii), based on a dry weight of component (i).
 36. The mineral fiber product of claim 24, wherein component (iii) is in the form of one or more plasticizers selected from fatty alcohols, monohydroxy alcohols; and/or one or more plasticizers selected from alkoxylates; and/or one or more plasticizers in the form of propylene glycols; and/or one or more plasticizers in the form of glycol esters; and/or one or more plasticizers selected from adipates, acetates, benzoates, cyclobenzoates, citrates, stearates, sorbates, sebacates, azelates, butyrates, valerates; and/or one or more plasticizers selected from phenol derivatives; and/or one or more plasticizers selected from silanols, siloxanes; and/or one or more plasticizers selected from sulfates, sulfonates, phosphates; and/or one or more plasticizers in the form of hydroxy acids; and/or one or more plasticizers selected from monomeric amides; and/or one or more plasticizers selected from quaternary ammonium compounds; and/or one or more plasticizers selected from vegetable oils; and/or tall oil; and/or one or more plasticizers selected from hydrogenated oils, acetylated oils; and/or one or more plasticizers selected from acid methyl esters; and/or one or more plasticizers selected from alkyl polyglucosides, gluconamides, aminoglucoseamides, sucrose esters, sorbitan esters; and/or one or more plasticizers selected from polyethylene glycols, polyethylene glycol ethers; and/or one or more plasticizers in the form of polyols; and/or triethanolamine.
 37. The mineral fiber product of claim 24, wherein component (iii) is in the form of propylene glycols, phenol derivatives, silanols, siloxanes, hydroxy acids, vegetable oils, polyethylene glycols, polyethylene glycol ethers, triethanolamine, or any mixtures thereof.
 38. The mineral fiber product of claim 24, wherein component (iii) comprises one or more plasticizers having a boiling point of from 100° C. to 380° C.
 39. The mineral fiber product of claim 24, wherein component (iii) comprises one or more polyethylene glycols having an average molecular weight of from 150 g/mmol to 50000 g/mol.
 40. The mineral fiber product of claim 24, wherein the product comprises from 0.5 wt.-% to 60 wt.-% of component (iii), based on a dry weight of component (i).
 41. The mineral fiber product of claim 24, wherein the aqueous binder composition further comprises urea.
 42. The mineral fiber product of claim 24, wherein the product does not contain an ammonia-oxidized lignin (AOL).
 43. A method of preparing a binder composition for mineral wool which is free of phenol and formaldehyde, wherein the method comprises employing one or more lignosulfonate lignins having a carboxylic acid group content of from 0.03 mmol/g to 1.4 mmol/g, based on a dry weight of the lignosulfonate lignins for making the binder composition. 